Object printed by a 3d printer and a method for determining the temperature of the object

ABSTRACT

An object printed by a three-dimensional (3D) printer includes a plurality of layers of material printed by the 3D printer. The layers of material bond together to form the object as the layers of material cool and solidify after being printed by the 3D printer. The object also includes a temperature sensor placed in contact with one or more of the layers when the layers of material are being printed by the 3D printer. The temperature sensor remains in contact with the object after the layers of material cool and solidify to form the object. The temperature sensor is configured to measure a temperature of the object after the layers of material cool and solidify to form the object.

TECHNICAL FIELD

The present teachings relate generally to three-dimensional (3D)printing and, more particularly, to systems and methods for determininga temperature of an object printed by a 3D printer.

BACKGROUND

A 3D printing process builds a three-dimensional object from acomputer-aided design (CAD) model, usually by successively depositingmaterial layer upon layer. For example, a first layer may be depositedupon a substrate, and then a second layer may be deposited upon thefirst layer. The temperature of the first layer and the temperature ofthe material being deposited upon the first layer to form the secondlayer should each be within a predetermined range to enable the layersto properly bond together and have the desired properties.

Oftentimes, non-contact temperature sensors are used to monitor thetemperature during the 3D printing process, so as to not obstruct orotherwise interfere with the 3D printing process. One type ofnon-contact temperature sensor that is used is called a pyrometer, whichmeasures an emissivity of a surface of the object during the 3D printingprocess. The emissivity refers to an effectiveness of emitting heatenergy as thermal radiation. The pyrometer has a memory with data storedtherein that corresponds to the type of material being printed. Usingthe measured emissivity and the data corresponding to the type ofmaterial being printed, the pyrometer may determine (e.g., predict) thetemperature of the object (e.g., using a look-up table).

However, the surface finish and/or the surface content of the materialbeing printed may vary, which may cause the temperature determinationsfrom the pyrometer to be inaccurate. Therefore, it would be beneficialto have an improved system and method for determining a temperature ofan object printed by a 3D printer.

SUMMARY

The following presents a simplified summary in order to provide a basicunderstanding of some aspects of one or more embodiments of the presentteachings. This summary is not an extensive overview, nor is it intendedto identify key or critical elements of the present teachings, nor todelineate the scope of the disclosure. Rather, its primary purpose ismerely to present one or more concepts in simplified form as a preludeto the detailed description presented later.

A system for determining a temperature of an object is disclosed. Thesystem includes a three-dimensional (3D) printer configured tosuccessively deposit a first layer of material, a second layer ofmaterial, and a third layer of material to form the object. The 3Dprinter is configured to form a recess in the second layer of material.The material is a metal. The system also includes a temperature sensorconfigured to be positioned at least partially with the recess and tohave the third layer deposited thereon. The temperature sensor isconfigured to measure a temperature of the first layer of material, thesecond layer of material, the third layer of material, or a combinationthereof.

A method for determining a temperature of an object is also disclosed.The method includes depositing a first layer of material onto asubstrate using a three-dimensional (3D) printer. The method alsoincludes positioning a temperature sensor on the first layer ofmaterial. The method also includes depositing a second layer of materialonto the first layer of material and the temperature sensor using the 3Dprinter. The method also includes measuring a temperature of the firstlayer of material, the second layer of material, or both using thetemperature sensor.

In another embodiment, the method includes depositing a first layer ofmaterial onto a substrate using a three-dimensional (3D) printer. Themethod also includes depositing a second layer of material onto thefirst layer of material using the 3D printer. The method also includesforming a recess in the second layer of material. The method alsoincludes positioning a temperature sensor at least partially in therecess such that the temperature sensor is in contact with the firstlayer of material, the second layer of material, or both. Thetemperature sensor is a thermocouple that includes two electricalconductors that are made of different materials. The method alsoincludes depositing a third layer of material onto the second layer ofmaterial and the temperature sensor using the 3D printer. The firstlayer of material, the second layer of material, and the third layer ofmaterial includes a metal. The method also includes measuring atemperature of the first layer of material, the second layer ofmaterial, the third layer of material, or a combination thereof usingthe temperature sensor.

An object printed by a three-dimensional (3D) printer is also disclosed.The object includes a plurality of layers of material printed by the 3Dprinter. The layers of material bond together to form the object as thelayers of material cool and solidify after being printed by the 3Dprinter. The object also includes a temperature sensor placed in contactwith one or more of the layers when the layers of material are beingprinted by the 3D printer. The temperature sensor remains in contactwith the object after the layers of material cool and solidify to formthe object. The temperature sensor is configured to measure atemperature of the object after the layers of material cool and solidifyto form the object.

In another embodiment, the object includes a first layer of materialprinted by the 3D printer. The object also includes a second layer ofmaterial printed by the 3D printer onto the first layer of material. Arecess is formed in the second layer of material. The object alsoincludes a third layer of material printed by the 3D printer onto thesecond layer of material. The first, second, and third layers ofmaterial bond together to form the object as the first, second, andthird layers of material cool and solidify after being printed by the 3Dprinter. The object also includes a first temperature sensor positionedat least partially within the recess when the first, second, and thirdlayers of material are being printed by the 3D printer. The firsttemperature sensor remains positioned at least partially within therecess after the first, second, and third layers of material cool andsolidify to form the object. The first temperature sensor is configuredto measure a temperature of the object before and after the first,second, and third layers of material cool and solidify to form theobject.

A method for determining a temperature of an object is also disclosed.The method includes printing the object using a three-dimensional (3D)printer. The method also includes measuring the temperature of theobject using a first temperature sensor while the object is beingprinted by the 3D printer. The first temperature sensor is in contactwith the object. The method also includes measuring the temperature ofthe object using the first temperature sensor after the object has beenprinted by the 3D printer.

A method for determining a temperature of an object is also disclosed.The method includes contacting the object with a first electricalconductor. A difference in electronegativity between the object and thefirst electrical conductor is greater than a predetermined value. Themethod also includes contacting the object or a substrate on which theobject is positioned with a second electrical conductor. A difference inelectronegativity between the object or the substrate and the secondelectrical conductor is less than the predetermined value. The methodalso includes connecting the first and second electrical conductorstogether. The method also includes measuring the temperature of theobject using the first and second electrical conductors. The first andsecond electrical conductors form at least a portion of a thermocouple.

A method for determining a temperature differential between two portionsof an object is also disclosed. The method includes contacting a firstportion of the object with a first end of an electrical conductor. Adifference in electronegativity between the object and the electricalconductor is greater than a predetermined value. The method alsoincludes contacting a second portion of the object with a second end ofthe electrical conductor. The method also includes determining atemperature differential between the first and second portions of theobject using the electrical conductor.

A method for determining a temperature differential between two portionsof an object is also disclosed. The method includes contacting a firstportion of the object with a first electrical conductor. A difference inelectronegativity between the object and the first electrical conductoris greater than a predetermined value. The method also includescontacting a second portion of the object with a second electricalconductor. A difference in electronegativity between the object and thesecond electrical conductor is greater than the predetermined value. Themethod also includes connecting the first and second electricalconductors together. The method also includes determining a temperaturedifferential between the first and second portions of the object usingthe first and second electrical conductors.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the presentteachings and together with the description, serve to explain theprinciples of the disclosure. In the figures:

FIG. 1 depicts a perspective view of a system for determining atemperature of an object printed by a 3D printer, according to anembodiment.

FIGS. 2A and 2B depict a flowchart of a method for determining thetemperature of the object, according to an embodiment.

FIG. 3 depicts a perspective view of the 3D printer depositing a firstlayer of material on a substrate, according to an embodiment.

FIG. 4 depicts a perspective view of the 3D printer depositing a secondlayer of material on the first layer of material, according to anembodiment.

FIG. 5 depicts a perspective view of a temperature sensor beingpositioned at least partially within a recess formed in the second layerof material, according to an embodiment.

FIG. 6 depicts a perspective view of the 3D printer depositing a thirdlayer of material on the second layer of material and the temperaturesensor, according to an embodiment.

FIG. 7 depicts a perspective view of the object after additional layershave been added, according to an embodiment.

FIG. 8 depicts a perspective view of a non-contact temperature sensordetermining the temperature of the object, according to an embodiment.

FIG. 9 depicts a side view of a vehicle with the object coupled thereto,according to an embodiment.

FIG. 10 depicts a flowchart of a method for determining a temperature ofthe object when the vehicle is in use, according to an embodiment.

FIG. 11 depicts a perspective view of another system for determining thetemperature of the object, according to an embodiment.

FIG. 12 depicts a flowchart of another method for determining thetemperature of the object, according to an embodiment.

FIG. 13 depicts a perspective view of another system for determining atemperature differential between two portions of the object, accordingto an embodiment.

FIG. 14 depicts a flowchart of a method for determining the temperaturedifferential between two portions of the object, according to anembodiment.

FIG. 15 depicts a perspective view of another system for determining thetemperature differential between two portions of the object, accordingto an embodiment.

FIG. 16 depicts a flowchart of another method for determining thetemperature differential between two portions of the object, accordingto an embodiment.

DETAILED DESCRIPTION

Reference will now be made in detail to exemplary embodiments of thepresent teachings, examples of which are illustrated in the accompanyingdrawings. Wherever possible, the same reference numbers will be usedthroughout the drawings to refer to the same, similar, or like parts.

FIG. 1 depicts a perspective view of a system 100 for determining atemperature of an object 150 printed by a 3D printer 120, according toan embodiment. The system 100 may include a support device 110. Thesupport device 110 may be or include a flat surface such as a table. Thesystem 100 may also include a substrate 112 positioned on the supportdevice 110.

The system 100 may also include the 3D printer 120, which may beconfigured to print the object 150 on the substrate 112. The system 100may also include a temperature sensor 130. The temperature sensor 130may be or include a thermocouple, a thermistor, or another temperaturesensor that may be placed in contact with the object 150 during and/orafter the 3D printing process. The temperature sensor (e.g.,thermocouple) 130 may produce a temperature-dependent voltage, and thetemperature of the object 150 may be determined based at least partiallyupon the voltage. The system 100 may also include a securing device 116which may be used to secure the temperature sensor 130 in place. In theembodiment shown, the securing device 116 may be or include a clamp thatis coupled to the support device (e.g., table) 110, and the temperaturesensor 130 may be secured in place between the support device (e.g., thetable) 110 and the clamp. The securing device 116 may help to hold thetemperature sensor 130 in contact with the object 150.

FIGS. 2A and 2B depicts a flowchart of a method 200 for determining thetemperature of the object 150, according to an embodiment. Anillustrative order of the method 200 is provided below; however, it willbe appreciated that one or more steps of the method 200 may be repeated,performed in a different order, and/or omitted altogether.

The method 200 may include depositing a first layer of material 151 ontothe substrate 112 using the 3D printer 120, as at 202. This is shown inFIG. 3. The material may be or include a metal or a polymer. Forexample, the material may be or include aluminum, brass, bronze, steel,stainless steel, titanium, or a combination thereof. The first layer ofmaterial 151 may have a thickness from about 25 μm to about 500 μm orabout 50 μm to about 250 μm.

The method 200 may also include depositing a second layer of material152 onto the first layer of material 151 using the 3D printer 120, as at204. This is shown in FIG. 4. The second layer of material 152 may be orinclude the same type of material (e.g., aluminum) as the first layer ofmaterial 151. The second layer of material 152 may have substantiallythe same thickness as the first layer of material 151.

The method 200 may also include forming a recess 160 in the second layerof material 152, as at 206. This is also shown in FIG. 4. In oneembodiment, the recess 160 may be formed by temporarily ceasing todeposit the material as the 3D printer 120 continues to move over thefirst layer of material 151. In other words, the recess 160 may beformed by the 3D printer 120. In another embodiment, the second layer ofmaterial 152 may be printed in a substantially uniform manner, and aportion of the second layer of material 152 may then be removed (e.g.,manually) to form the recess 160.

The method 200 may also include positioning at least a portion of afirst temperature sensor 130 at least partially into the recess 160, asat 208. This is shown in FIG. 5. The first temperature sensor 130 may beor include a thermocouple that includes two electrical conductors 132A,132B (see FIG. 1) that are made of different materials. In an example,the two electrical conductors 132A, 132B may be in contact with oneanother, such that a hot junction (e.g., conductor 132A) is formedwithin or in contact with the object 150, and a cold junction (e.g.,conductor 132B) is formed away from the object 150. The property ofdissimilarity of the metals may represent a difference inelectronegativity. In another embodiment, the first temperature sensor130 may also or instead be a thermistor (e.g., a glass-encapsulatedthermistor). The electrical conductors 132A, 132B may have a length fromabout 2 mm to about 50 mm or about 5 mm to about 25 mm. The electricalconductors 132A, 132B may have a thickness from about 250 μm to about1800 μm or about 500 μm to about 1000 μm.

The recess 160 may be sized and shaped based at least partially upon thesize of the electrical conductors 132A, 132B. This may maximize thesurface area of the electrical conductors 132A, 132B that is in contactwith the first layer of material 151, the second layer of material 152,the third layer of material 153 (described below), or a combinationthereof. For example, the length of the recess 160 may be substantiallythe same as the length of the electrical conductors 132A, 132B. Inaddition, the depth of the recess 160 may be substantially the same asthe thickness of the electrical conductors 132A, 132B. In an embodimentwhere the thickness of the electrical conductors 132A, 132B is greaterthan the second layer of material 152, then the recess 160 may be formedin a plurality of stacked layers such that the depth of the recess 160is substantially the same as the thickness of the electrical conductors132A, 132B.

The method 200 may also include depositing a third layer of material 153onto the second layer of material 152 using the 3D printer 120, as at210. This is shown in FIG. 6. The third layer of material 153 may be orinclude the same type of material (e.g., aluminum) as the first layer ofmaterial 151 and/or the second layer of material 152. The third layer ofmaterial 153 may have substantially the same thickness as the firstlayer of material 151 and/or the second layer of material 152.

The third layer of material 153 may also be deposited onto the firsttemperature sensor 130 (e.g., the electrical conductors 132A, 132B).Thus, the first temperature sensor 130 (e.g., the electrical conductors132A, 132B) may be in contact with (e.g., embedded at least partiallywithin) the first layer of material 151, the second layer of material152, and/or the third layer of material 153.

Placing the first temperature sensor 130 (e.g., the electricalconductors 132A, 132B) in the recess 160 may allow the third layer ofmaterial 153 to be substantially flat over the first temperature sensor130. In at least one embodiment, the recess 160 may be omitted, and thefirst temperature sensor 130 may be placed on top of the first layer ofmaterial 151 and/or the second layer of material 152, and the thirdlayer of material 153 may be deposited thereon; however, this may resultin the portion of the third layer of material 153 that is positionedover the first temperature sensor 130 protruding slightly outward (e.g.,upward).

The material may have a temperature from about 500° C. to about 800° C.or about 550° C. to about 700° C. when the material is discharged fromthe 3D printer 120 and deposited onto the substrate 112 and/or thepreviously-printed layer. The material may gradually cool down to belowthe melting point of the material, which allows the material to solidifyto form the object 150. For example, the material may gradually cool toan ambient temperature between about 10° C. and about 30° C.

As the layers of material 151-153 are printed successively (i.e., oneafter the other), there may be a temperature differential between thelayers of material 151-153 during the printing process. For example, thefirst layer of material 151 may have cooled down to a temperature fromabout 400° C. to about 650° C. or about 450° C. to about 550° C. as thesecond layer of material 152 is deposited onto the first layer ofmaterial 151. Similarly, the second layer of material 152 may havecooled down to a temperature from about 400° C. to about 650° C. orabout 450° C. to about 550° C. as the third layer of material 153 isdeposited onto the second layer of material 152.

The method 200 may also include measuring a temperature of the object150 using the first temperature sensor 130, as at 212. The temperaturemay be measured during and/or after the 3D printing process. In oneembodiment, the temperature of the first layer of material 151 may bemeasured before, simultaneously with, and/or after the second layer ofmaterial 152 is deposited thereon. In another embodiment, thetemperature of the second layer of material 152 may be measured before,simultaneously with, and/or after the third layer of material 153 isdeposited thereon. In another embodiment, the temperature of the thirdlayer of material 153 may be measured simultaneously with and/or afterthe third layer of material 153 is deposited. In yet another embodiment,the temperature of the first layer of material 151, the second layer ofmaterial 152, the third layer of material 153, or a combination thereofmay be measured after the object 150 has finished cooling (e.g., at anambient temperature) and/or after the object 150 has solidified.

Measuring the temperature of the object 150 may also or instead includemeasuring the temperature differential between the first layer ofmaterial 151 and the second layer of material 152, between the secondlayer of material 152 and the third layer of material 153, between thefirst layer of material 151 and the third layer of material 153, or acombination thereof using the first temperature sensor 130. In at leastone embodiment, measuring the temperature differential may include usingtwo or more temperature sensors that are in contact with differentlayers of material. For example, a first temperature sensor (e.g.,thermocouple) may be positioned in contact with and/or at leastpartially between the first layer of material 151 and the second layerof material 152, and a second temperature sensor (e.g., thermocouple)may be positioned in contact with and/or at least partially between thesecond layer of material 152 and the third layer of material 153.

The method 200 may also include varying the temperature of the object150 in response to the temperature measured by the first temperaturesensor 130, as at 214. The temperature of the object 150 may be variedduring and/or after the printing process. As mentioned above, during theprinting process, it may be desirable to maintain the temperature of thematerial being deposited within a first predetermined range, and/or thetemperature of the substrate 112 and/or previously-printed layer uponwhich the material is being deposited within a second predeterminedrange. The first predetermined range may be from about 500° C. to about800° C. or about 550° C. to about 700° C., and the second predeterminedrange may be from about 300° C. to about 650° C. or about 300° C. toabout 500° C. These ranges may provide optimal bonding properties of thelayers of material 151-153.

The temperature of the object 150 may be increased using, for example, aheater 170. The heater 170 may be or include a convection heater thatmay be used to increase the temperature of the substrate 112, the firstlayer of material 151, the second layer of material 152, the third layerof material 153, or a combination thereof. The temperature of the object150 may also or instead be decreased using, for example, a cooler 172.The cooler 172 may be a forced convective air stream from a systemincluding one or more of: a heat exchanger, water or coolant chiller,thermoelectric cooler, cryogenic cooler, or Ranque-Hilsch vortex tubethat may be used to decrease the temperature of the substrate 112, thefirst layer of material 151, the second layer of material 152, the thirdlayer of material 153, or a combination thereof.

In another embodiment, instead of, or in addition to, varying thetemperature of the object 150, the temperature of the material beingdeposited may be varied. More particularly, the temperature of thematerial in the 3D printer 120 may be varied (e.g., increased ordecreased). In yet another embodiment, instead of, or in addition to,varying the temperature of the object 150 or the material in the 3Dprinter 120, the speed of the 3D printer 120 may be varied. For example,the speed of the 3D printer 120 may be increased, which may reduce thetime that the previously-printed layer has to cool. Thus, increasing thespeed of the 3D printer 120 may cause the temperature of thepreviously-printed layer to be greater than it would be at the previousprinting speed. In another example, the speed of the 3D printer 120 maybe decreased, which may increase the time that the previously-printedlayer has to cool. Thus, decreasing the speed of the 3D printer 120 maycause the temperature of the previously-printed layer to be lesser thanit would be at the previous printing speed.

In at least one embodiment, the method 200 may also include depositingone or more additional layers of material (three layers are shown:154-156) using the 3D printer 120, as at 216. This is shown in FIG. 7.For example, the fourth layer of material 154 may be deposited onto thethird layer of material 153, the fifth layer of material 155 may bedeposited onto the fourth layer of material 154, and the sixth layer ofmaterial 156 may be deposited onto the fifth later of material 155.

The layers of material 151-153 may be substantially uniform. In otherwords, the layers of material 151-153 may have substantially the samelength, width, and depth/thickness. However, in the embodiment shown inFIG. 7, the additional layers of material 154-156 may have a differentlength, width, and/or depth/thickness. For example, the layers 154-156may have a lesser length and a lesser width. This difference in size maycause the layers of material 154-156 to cool at a different rate thanthe layers of material 151-153. More particularly, the lesser lengthand/or lesser width may cause the layers of material 154-156 to coolmore rapidly than the layers of material 151-153.

The method 200 may also include forming a recess 161 in the fifth layerof material 155, as at 218. This is also shown in FIG. 7. This may besimilar to step 206 and is not described again here in detail. Themethod 200 may also include positioning at least a portion of a secondtemperature sensor 131 at least partially into the recess 161, as at220. This is also shown in FIG. 7. This may be similar to step 208 andis not described again here in detail.

Thus, two or more temperature sensors (two are shown: 130, 131) may beplaced in contact with the object 150 at/in different locations. Asdescribed above, the first temperature sensor 130 may be positioned atleast partially within the object 150 at a first location where theobject 150 has a first size. More particularly, the first temperaturesensor 130 may be positioned (e.g., embedded) at least partially betweenthe first layer of material 151 and the third layer of material 153. Thesecond temperature sensor 131 may be positioned at least partiallywithin the object 150 at a second location where the object 150 has asecond size that is different than the first size (e.g., a differentlength, width, and/or depth/thickness). More particularly, the secondtemperature sensor 131 may be positioned (e.g., embedded) at leastpartially between the fourth layer of material 154 and the sixth layerof material 156.

The method 200 may also include measuring a temperature of the object150 using the second temperature sensor 131, as at 222. As mentionedabove, this may yield measurements that indicate that one or more of thelayers of material 151-153 are cooling at a different (e.g., slower)rate than one or more of the layers of material 154-156 due to thedifferent sizes.

The method 200 may also include varying the temperature of the object150 in response to the temperature measured by the second temperaturesensor 131, as at 224. When the temperature measured at 222 indicatesthat the layers of material 154-156 are cooling at a different (e.g.,slower) rate than the temperature measured at 212 for the layers ofmaterial 151-153, then the varying of the temperature at 224 may differfrom the varying of the temperature at 214. For example, the heater 170may provide more heat to the layers of material 154-156 than it does/didto the layer of material 151-153 to maintain substantially uniformcooling of all of the layers of material 151-156.

In at least one embodiment, the method 200 may also include measuringthe temperature of the object 150 using a third temperature sensor 180,as at 226. This is shown in FIG. 8. The third temperature sensor 180 maybe a non-contact temperature sensor that is configured to measure thetemperature of the object 150 without contacting the object 150. Thethird temperature sensor 180 may be or include a pyrometer that focuseson a particular portion of a surface area of the object 150 and measuresthe temperature thereof without contacting the object 150.

The third temperature sensor 180 may be configured to measure thetemperature of the object 150 in substantially the same location as thefirst temperature sensor 130 and/or the second temperature sensor 131.As used herein, substantially the same location refers to within about10 mm or less, within about 5 mm or less, within about 3 mm or less, orwithin about 1 mm or less. When the first temperature sensor 130 isembedded between two or more of the layers of material 151-153, thethird temperature sensor 180 may be pointed at the first temperaturesensor 130. For example, the third temperature sensor 180 may be focusedon a portion of the third layer of material 153 that is directlyadjacent to (e.g., above) the first temperature sensor 130. Thus, thedistance between the first temperature sensor 130 and the location wherethe third temperature sensor 180 is focused may be about the thicknessof the third layer of material 153.

The third temperature sensor 180 may measure the temperature of theobject 150 during and/or after the 3D printing process. In oneembodiment, the third temperature sensor 180 may measure the temperatureof the first layer of material 151 before, simultaneously with, and/orafter the second layer of material 152 is deposited thereon. In anotherembodiment, the third temperature sensor 180 may measure the temperatureof the second layer of material 152 before, simultaneously with, and/orafter the third layer of material 153 is deposited thereon. In anotherembodiment, the third temperature sensor 180 may measure the temperatureof the third layer of material 153 simultaneously with and/or after thethird layer of material 153 is deposited. In yet another embodiment, thethird temperature sensor 180 may measure the temperature of the firstlayer of material 151, the second layer of material 152, the third layerof material 153, or a combination thereof after the object 150 hasfinished cooling (e.g., at an ambient temperature) and/or after theobject 150 has solidified.

As mentioned above, a non-contact temperature sensor may sometimes beinaccurate. Thus, the method 200 may also include calibrating the thirdtemperature sensor 180 using the measurement(s) from the firsttemperature sensor 130, as at 228. The calibration may include creatingor altering lookup tables or equations that correlate data collected bythe third temperature sensor 180 to a temperature reading (e.g., fromthe first temperature sensor 130). For example, the third temperaturesensor 180 may collect and measure the strength of infrared radiationfrom the object 150 at one or more specific wavelengths, and use lookuptables or equations programmed into the third temperature sensor 180 orthe controller to output a temperature or temperature range to a user.In one embodiment, the system 100 is able to print pre-programmed testobjects 150 that contain temperature sensors 130 and/or 131 andautomatically compare the temperature data from those sensors 130, 131to values obtained from the third temperature sensor 180 in order toautomatically improve the accuracy of the readings from the thirdtemperature sensor 180. In another embodiment, the user collects thedata from temperature sensors 130 and/or 131 and uses that data toadjust the third temperature sensor 180. The temperature sensors 130,131 may be used during manufacture of the printer 120 to calibrate thethird temperature sensor 180 before sending to a customer.Alternatively, if a customer is going to be printing a large quantity ofthe same or similar objects, they may use this method to dial in thesystem 100 for that geometry and ensure the larger batch comes out withhighest quality.

Measuring a Temperature of the Object after Printing is Completed

After the object 150 has been printed (i.e., the printing process iscomplete), the object 150 may cool and solidify, and the layers 151-156may bond together. The object 150 may then be removed from the substrate112. The sensor(s) 130, 131 may remain in contact with (e.g., at leastpartially embedded within) the object 150 while the object 150 cools andsolidifies and thereafter. In addition to measuring the temperature ofthe object 150 as the object 150 is being printed, as described above,the temperature sensor(s) 130, 131 may also or instead be used tomeasure the temperature of the object 150 after the object 150 has beenprinted, as described below.

In one embodiment, the object 150 may be or include a standalone objectthat is not coupled to anything else such as a container that storesfood and/or drinks, a container that cooks food and/or drinks, a handtool, or the like. In another embodiment, the object 150 may beconfigured to be coupled to something else such as a vehicle, a turbine,a battery pack, a heat sink, a heat exchanger, an electric motor, acombustion engine, an enclosure for an electronic device, a power tool,a fluid control valve, a fluid fitting or coupler, a power conductor, astructural component, or the like. For example, the object 150 may be agusset on the vehicle, a fuel nozzle on the vehicle, a part of an engineor motor of the vehicle, or the like. In the embodiments above, theobject 150 may have a primary function (e.g., the gusset may be astructural support on the vehicle), and measuring the temperature may bea secondary function of the object 150. However, in other embodiments,the primary function of the object 150 may be measuring the temperature.For example, the object 150 may be or include a customized temperatureprobe that is shaped (e.g., during the method 200 described above) tohave a sheath shape, a thermal interface, or a physical mounting that iscustomized for standalone use or installation into a larger system.Forming this shape, interface, and/or mounting using the 3D printer 120may allow for more customization and integrate the probe directly intothe sheath without secondary operations.

FIG. 9 depicts a side view of a vehicle 900 with the object 150 coupledthereto, according to an embodiment. After the object 150 cools andsolidifies, the object 150 may be coupled to the vehicle 900. The object150 may be coupled to an exterior of the vehicle 900, or the object 150may be coupled to or otherwise positioned within the vehicle 900. Thevehicle 900 may be or include a car, a truck, a bus, a train, a boat, anairplane, a helicopter, a drone, a spacecraft, etc. The object 150 maybe a metallic (e.g., aluminum) component on/in the vehicle 900. In theexample shown, the vehicle 900 is an aircraft (e.g., an airplane), andthe object 150 is a gusset on a wing 910 of the airplane 900. Althoughreference number 900 refers to a vehicle, it may also or instead referto any other item to which the object 150 may be coupled (e.g., aturbine, battery pack, heat sink, etc.).

FIG. 10 depicts a flowchart of a method 1000 for determining atemperature of the object 150 after the object 150 has been printed,according to an embodiment. An illustrative order of the method 1000 isprovided below; however, it will be appreciated that one or more stepsof the method 1000 may be repeated, performed in a different order,and/or omitted altogether.

The method 1000 may include coupling the object 150 to the vehicle 900,as at 1002. The object 150 may be coupled to the vehicle 900 using amechanical fastener (e.g., a screw, a nut, a bolt, a nail, a strap,etc.), an adhesive, or the like.

The method 1000 may also include starting the vehicle 900, as at 1004.Once the vehicle 900 is started, the vehicle 900 may be “in use” whichis also referred to as an “on” state. The method 1000 may also includemoving the vehicle 900, as at 1006. The vehicle 900 may move on theground (e.g., taxi on a runway) and/or may move in the air (e.g., inflight). If the object 150 is a standalone object, then one or moresteps (e.g., 1002, 1004, 1006) may be omitted.

The method 1000 may also include measuring a temperature of the object150 using the first temperature sensor 130, as at 1008. The method 1000may also or instead include measuring the temperature of the object 150using the second temperature sensor 131, as at 1010. The temperature ofthe object 150 may be measured before the vehicle 900 is started, whilethe vehicle 900 is in the on state, and/or after the vehicle 900 isturned into an off state. The temperature of the object 150 may also orinstead be measured before the vehicle 900 moves, while the vehicle 900is moving, and/or after the vehicle 900 has finished moving.

As mentioned above with reference to FIGS. 7 and 8, the first and secondtemperature sensors 130, 131 may be in contact with (e.g., coupled toand/or embedded within) different portions of the object 150. Moreparticularly, the first temperature sensor 130 may be in contact with afirst portion of the object 150 that has a first size (e.g., length,width, and/or thickness), and the second temperature sensor 131 may bein contact with a second portion of the object 150 that has a secondsize that is different than the first size. In the example shown inFIGS. 7 and 8, the first portion may be or include the layers 151, 152,153, or a combination thereof, and the second portion may be or includethe layers 154, 155, 156, or a combination thereof. In this particularexample, the second portion has a lesser size (e.g., length and/orwidth) than the first portion and thus may heat and/or cool more quicklythan the first portion. Thus, the temperature sensors 130, 131 maymeasure different temperatures at the same time, even when exposed tothe same ambient temperature.

The object 150 may be designed to maintain (e.g., operate within) apredetermined temperature range (e.g., a normal operating range) afterthe object 150 has been printed, which may have a lower limit and anupper limit. In an example where the object 150 is a gusset on the wing910, the lower limit may be about −56° C., and the upper limit may beabout 510° C. In another example where the object 150 is a componentin/on a jet engine or an exhaust of an aircraft, the upper limit may beabout 2000° C. In yet another example where the object 150 is acomponent in/on a spacecraft (e.g., a satellite in orbit around theEarth), the lower limit may be about −250° C. or about −170° C., and theupper limit may be about 130° C. or about 300° C. In yet another examplewhere the object 150 is a component in/on a space capsule, rocket, orspaceplane, the lower limit may be about −250° C., and the upper limitmay be about 2700° C.

The method 1000 may also include varying the temperature of the object150 in response to the temperature measured by the first temperaturesensor 130, as at 1012. The temperature of the object 150 may also orinstead be varied in response to the temperature measured by the secondtemperature sensor 131, as at 1014. In an embodiment, if the temperatureof the object 150 is less than the lower limit, the temperature of theobject 150 may be increased using, for example, the heater 170 (oranother heater). If the temperature of the object 150 is greater thanthe upper limit, the temperature of the object 150 may be decreasedusing, for example, the cooler 172 (or another cooler). The heater 170and/or the cooler 172 may be coupled to the vehicle 900.

In another embodiment where the vehicle 900 is an aircraft, thetemperature of the object 150 may be varied by adjusting the altitudeand/or flight patterns of the vehicle 900 automatically or with partialuser intervention. For example, in response to the measured temperaturebeing below a lower limit (e.g., such that ice may form on the object150 and/or the wing 910), the altitude of the vehicle 900 may be reducedto a level where warmer air exists. In another example, in response tothe measured temperature being above an upper limit, the altitude of thevehicle 900 may be increased to a level where colder air exists. Inanother example, in response to the measured temperatures being belowthe lower limit, the flight pattern of the vehicle 900 may be adjustedbased at least partially upon weather and/or atmosphere data to flythrough warmer air. In another example, in response to the measuredtemperatures being above the upper limit, the flight pattern of thevehicle 900 may be adjusted based at least partially upon weather and/oratmosphere data to fly through colder air.

In an embodiment where the vehicle 900 is a car with a combustionengine, the object 150 may be designed to operate at an upper limit ofabout 280° C., or to be exposed to combustion reactions with an upperlimit of about 2500° C. In response to the measured temperature beingabove the upper limit, an operator of vehicle 900 (e.g., the driver) maybe notified or instructed to reduce the power output of the engine invehicle 900, or shut off power to vehicle 900. In an embodiment wherevehicle 900 is powered by a diesel engine, the temperature of the engineor the diesel fuel may be designed to operate above a lower limit (e.g.,the known cloud point of the diesel fuel in the vehicle 900), belowwhich the vehicle 900 may have difficulty starting or operating. Inresponse to the measured temperature being below the lower limit, theoperator of the vehicle 900 may be notified or instructed to turn on theheater 170 (or another heater). In an embodiment where the vehicle 900includes an electric propulsion system, a battery pack, batteryenclosure, electronics enclosure, motor, transmission, etc., one or moreof these components may be designed to operate within a predeterminedtemperature range during storage or operation. In response to themeasured temperature being outside of the predetermined temperaturerange, the operator of the vehicle 900 may be notified or instructed toadjust the heater 170 and/or the cooler 172 or to adjust the poweroutput of the vehicle 900.

In an embodiment, the temperatures measured by the sensor(s) 130, 131may be transmitted to a computing system (e.g., in the vehicle 900), andthe computing system may then actuate the heater 170, actuate the cooler172, and/or vary the altitude or flight pattern in response to themeasured temperatures. The computing system may also or instead alert anoperator (e.g., driver or pilot) of vehicle 900 that the measuredtemperatures that are within or outside of the predetermined temperaturerange, for example, by turning alert lights on or off or displayingmessages on a user interface. The computing system may also or insteadrecord the measured temperatures to a memory storage device withinvehicle 900 such as a black box recorder, a hard drive, a flash memory,or another storage device. The computing system may also or insteadtransmit the measured temperatures to another system outside of thevehicle 900, such as to a central database or central control center. Inthe example where the vehicle 900 is an aircraft, the central databaseor central control center may be to an air traffic control station.

As mentioned above, the temperature sensors 130, 131 may measuredifferent temperatures at the same time. If, for example, onetemperature sensor (e.g., the first temperature sensor 130) measures atemperature that is within the predetermined temperature range, and theother temperature sensor (e.g., the second temperature sensor 131)measures a temperature that is less than the lower limit of thepredetermined temperature range, then the temperature of the object 150may be increased using any of the techniques discussed above. In anotherexample, if one temperature sensor (e.g., the first temperature sensor130) measures a temperature that is within the predetermined temperaturerange, and the other temperature sensor (e.g., the second temperaturesensor 131) measures a temperature that is greater than the upper limitof the predetermined temperature range, then the temperature of theobject 150 may be decreased using any of the techniques discussed above.

Thus, the temperature sensor(s) 130, 131 may be used to measure thetemperature of the object 150 during the 3D printing process (e.g., asdescribed at 212 and/or 222 in FIG. 2), after the 3D printing process(as described at 1008 and/or 1010 in FIG. 10), or both.

Measuring a Temperature of the Object Using the Object as Part of theThermocouple

The embodiments above use temperatures sensors (e.g., thermocouples)130, 131, 180 that function as standalone sensors that is/are placed incontact with (e.g., embedded in) the object 150 during the 3D printingprocess. In an example, before being placed in contact with the object150, these temperature sensors 130, 131, 180 may be coupled to and/orpart of a reader (e.g., a thermocouple reader) and used to measure atemperature of the air, a temperature of a human body (e.g., whenpinched between two fingers), etc. As mentioned above, thermocoupleswork by having two electrical conductors (e.g., wires) that are made ofdissimilar materials (e.g., metals), and the dissimilar materials have adifference in electronegativity. The embodiments below use the object150 as one of the two dissimilar metals that form the thermocouple.

FIG. 11 depicts a perspective view of a system 1100 for determining thetemperature of the object 150, according to an embodiment. The system1100 may include a first electrical conductor 132A, a second electricalconductor 132B, and a thermocouple reader 190. In an example, theelectrical conductors 132A, 132B and/or the thermocouple reader 190 maybe configured to measure the temperature of the object 150 during and/orafter printing of the object 150.

At least a portion of the electrical conductors 132A, 132B and theobject 150 may be positioned within a heated zone 122. Another portionof the electrical conductors 132A, 132B and the thermocouple reader 190may be positioned outside of the heated zone 122. The heated zone 122may be or include an area or volume that may have an elevated gas (e.g.,air) temperature during printing of the object 150. The elevatedtemperature may be greater than a predetermined threshold. Thepredetermined threshold may be about 30° C., about 50° C., or about 100°C. In one example, the heated zone 122 may be within the 3D printer 120.

The first electrical conductor 132A may be in contact with the object150 during and/or after the printing of the object 150. Moreparticularly, a first end 134A of the first electrical conductor 132Amay be embedded within the object 150 during the printing of the object150, as described above. Thus, the first end 134A and the object 150 maybe positioned within the heated zone 122. The point where the first end134A is in contact with the object 150 may be referred to as a firstjunction 136. The first electrical conductor 132A may be made of adifferent material than the object 150. The first electrical conductor132A may also or instead have a different electronegativity value thanthe object 150. In an example, the difference in electronegativityvalues may be greater than or equal to a predetermined value. Thepredetermined value may be from about 0.1 to about 0.5 or about 0.2 toabout 0.4. For example, the predetermined value may be about 0.3.

The second electrical conductor 132B may also be in contact with theobject 150 during and/or after the printing of the object 150. Moreparticularly, a first end 134B of the second electrical conductor 132Bmay be embedded within the object 150 during the printing of the object150, as described above. Thus, the first end 134B may also be positionedwithin the heated zone 122. As shown, the first ends 134A, 134B may bein contact with different portions (e.g., different layers 151-156) ofthe object 150. The different portions may have different temperatures(e.g., due to being printed at different times). The second electricalconductor 132B may be made of substantially the same material as theobject 150. The second electrical conductor 132B may also or insteadhave substantially the same electronegativity value as the object 150.In an example, the difference in electronegativity values between thesecond electrical conductor 132B and the object 150 may be less than orequal to the predetermined value.

In another embodiment (shown in dashed lines), the second electricalconductor 132B may instead be in contact with the substrate (e.g., baseplate) 112 during and/or after the printing of the object 150. Thus, thefirst end 134B may be positioned within the heated zone 122. In thisembodiment, the second electrical conductor 132B and/or the substrate112 may be made of substantially the same material as the object 150. Inthis embodiment, the second electrical conductor 132B and/or thesubstrate 112 may also or instead have substantially the sameelectronegativity value as the object 150. For example, the differencein electronegativity values between the second electrical conductor 132Band the object 150 may be less than or equal to the predetermined value,and/or the difference in electronegativity values between the substrate112 and the object 150 may be less than or equal to the predeterminedvalue.

FIG. 12 depicts a flowchart of a method 1200 for determining thetemperature of the object 150, according to an embodiment. Anillustrative order of the method 1200 is provided below; however, itwill be appreciated that one or more steps of the method 1200 may berepeated, performed in a different order, and/or omitted altogether.

The method 1200 may include printing the object 150 with the 3D printer120, as at 1202. This may be similar to at least a portion of the method200 described above with reference to FIGS. 2A, 2B, and 3-8.

The method 1200 may also include contacting the object 150 with thefirst electrical conductor 132A, as at 1204. More particularly, this mayinclude embedding the first end 134A of the first electrical conductor132A at least partially within the object 150 during the printing of theobject 150. This may be similar to steps 202-210 in FIG. 2A and FIGS.3-6, as described above. The first electrical conductor 132A may be incontact with the object 150 during and/or after the printing of theobject 150.

The method 1200 may also include contacting the object 150 with thesecond electrical conductor 132B, as at 1206. More particularly, thismay include embedding the first end 134B of the second electricalconductor 132B at least partially within the object 150 during theprinting of the object 150. This may be similar to steps 216-220 in FIG.2B and FIG. 7, as described above. The second electrical conductor 132Bmay be in contact with the object 150 during and/or after the printingof the object 150.

Optionally, step 1206 may be omitted, and the method 1200 may insteadinclude contacting the substrate 112 with the second electricalconductor 132B, as at 1208. In this embodiment, the second electricalconductor 132B may be in contact with the substrate 112 during and/orafter the printing of the object 150.

The method 1200 may also include connecting the first electricalconductor 132A and the second electrical conductor 132B, as at 1210.More particularly, this may include connecting a second end 135A of thefirst electrical conductor 132A and a second end 135B of the secondelectrical conductor 132B. This connection may be referred to as asecond (e.g., reference) junction. The second ends 135A, 135B and/or thesecond junction may be located outside of the heated zone 122 (e.g.,outside of the 3D printer 120). The gas (e.g., air) temperature aroundthe second junction (e.g., outside of the heated zone 122) may be lessthan the temperature around first junction 136 (e.g., inside the heatedzone 122). For example, the temperature around the second junction maybe less than threshold (e.g., less than about 100° C., less than about50° C., or less than about 30° C.).

The method 1200 may also include connecting the first electricalconductor 132A and the second electrical conductor 132B to thethermocouple reader 190, as at 1212. More particularly, the second ends135A, 135B may be connected to the thermocouple reader 190.

The method 1200 may also include measuring a temperature of the object150 using the first and second electrical conductors 132A, 132B and thethermocouple reader 190, as at 1214. A thermocouple is formed at thefirst junction 136 (e.g., at the interface between the first end 134A ofthe first electrical conductor 132A and the object 150). Thethermocouple reader 190 may be configured to measure a temperature atthe first junction 136 (e.g., in relation to the second junction) todetermine the temperature of the object 150 proximate to the firstjunction 136.

FIG. 13 depicts a perspective view of a system 1300 for determining atemperature differential between two portions of the object 150,according to an embodiment. The system 1300 may include a singleelectrical conductor 132A.

The electrical conductor 132A may be in contact with the object 150during and/or after the printing of the object 150. The first end 134Aof the electrical conductor 132A may be in contact with (e.g., embeddedwithin) the object 150 during the printing of the object 150. Moreparticularly, the first end 134A may be in contact one or more of layers153-153, as shown in FIGS. 3-6. For example, the first end 134A may bepositioned at least partially within the recess 160. The point where thefirst end 134A is in contact with the object 150 may be referred to asthe first junction 136.

The second end 135A of the electrical conductor 132A may also be incontact with (e.g., embedded within) the object 150 during the printingof the object 150. The second end 135A may be embedded within adifferent portion of the object 150 than the first end 134A. Moreparticularly, the second end 135A may be in contact one or more oflayers 154-156, as shown in FIGS. 7 and 8. For example, the second end135A may be positioned at least partially within the recess 161. Thepoint where the second end 135A is in contact with the object 150 may bereferred to as the second junction 137.

The electrical conductor 132A may be made of a different material thanthe object 150. The electrical conductor 132A may also or instead have adifferent electronegativity value than the object 150. In an example,the difference in electronegativity values may be greater than or equalto a predetermined value. The predetermined value may be from about 0.1to about 0.5 or about 0.2 to about 0.4. For example, the predeterminedvalue may be about 0.3.

FIG. 14 depicts a flowchart of a method 1400 for determining atemperature differential between two portions of the object 150,according to an embodiment. An illustrative order of the method 1400 isprovided below; however, it will be appreciated that one or more stepsof the method 1400 may be repeated, performed in a different order,and/or omitted altogether.

The method 1400 may include printing the object 150 with the 3D printer120, as at 1402. This may be similar to at least a portion of the method200 described above with reference to FIGS. 2A, 2B, and 3-8.

The method 1400 may include contacting a first portion of the object 150with the first end 134A of the electrical conductor 132A, as at 1404.More particularly, this may include embedding the first end 134A atleast partially within the object 150 during the printing of the object150. This may be similar to steps 202-210 in FIG. 2A and FIGS. 3-6, asdescribed above. The first end 134A of the electrical conductor 132A maybe in contact with the object 150 during and/or after the printing ofthe object 150.

The method 1400 may also include contacting a second portion of theobject 150 with the second end 135A of the electrical conductor 132A, asat 1406. More particularly, this may include embedding the second end135A of the electrical conductor 132A at least partially within theobject 150 during the printing of the object 150. This may be similar tosteps 216-220 in FIG. 2B and FIG. 7, as described above. The second end135A of the electrical conductor 132A may be in contact with the object150 during and/or after the printing of the object 150.

As will be appreciated, the first and second portions of the object 150may have different temperatures. For example, the first portion may beor include one or more of the layers 151-153, and the second portion maybe or include one or more of the layers 154-156 (see FIGS. 3-8). Asdescribed above, the layers 151-153 may be deposited/printed before thelayers 154-156, and thus the layers 151-153 may be cooler than thelayers 154-156. In one embodiment, the temperature of the object 150 maybe varied (e.g., using the substrate 112, the heater 170, and/or thecooler 172), as described above with respect to steps 214, 224. This maycause the first portion and the second portion of the object 150 to havedifferent temperatures.

The method 1400 may also include determining a temperature differentialbetween the first and second portions of the object 150 using theelectrical conductor 132A, as at 1408. The temperature differentialbetween the first and second portions (i.e., the first and secondjunctions 136, 137) may create an electro-motive force, which causes avariation (e.g., increase) in voltage that corresponds to thetemperature differential. Thus, determining the temperature differentialmay include measuring a voltage differential between the first andsecond portions of the object 150 using the electrical conductor 132A. Alookup table and/or an equation may then be used to determine thetemperature differential based at least partially upon the voltagedifferential.

In at least one embodiment, the method 1400 may also include varying thetemperature of the object 150 in response to the temperaturedifferential, as at 1410. This may be similar to step 214, 224, 1012,1014, or a combination thereof, and for the sake of brevity, the detailsare not discussed again here.

FIG. 15 depicts a perspective view of another system 1500 fordetermining the temperature differential between two portions of theobject 150, according to an embodiment. The system 1500 is similar tothe system 1300, except two electrical conductors 132A, 132B are used.

The first electrical conductor 132A may be in contact with the object150 during and/or after the printing of the object 150. The first end134A of the electrical conductor 132A may be in contact with (e.g.,embedded within) the object 150 during the printing of the object 150.The first end 134A may be in contact one or more of layers 153-153, asshown in FIGS. 3-6. For example, the first end 134A may be positioned atleast partially within the recess 160. The point where the first end134A is in contact with the object 150 may be referred to as the firstjunction 136.

The second end 134B of the second electrical conductor 132B may also bein contact with (e.g., embedded within) the object 150 during theprinting of the object 150. The second end 134B may be embedded within adifferent portion of the object 150 than the first end 134A. Moreparticularly, the second end 134B may be in contact one or more oflayers 154-156, as shown in FIGS. 7 and 8. For example, the second end134B may be positioned at least partially within the recess 161. Thepoint where the second end 134B is in contact with the object 150 may bereferred to as the second junction 137.

The second end 135A of the first electrical conductor 132A and thesecond end 135B of the second electrical conductor 132B may be connectedtogether. The electrical conductors 132A, 132B may be made of the samematerial, which may be a different material than the object 150. Theelectrical conductors 132A, 132B may also or instead have a differentelectronegativity value than the object 150. In an example, thedifference in electronegativity values may be greater than or equal to apredetermined value. The predetermined value may be from about 0.1 toabout 0.5 or about 0.2 to about 0.4. For example, the predeterminedvalue may be about 0.3.

FIG. 16 depicts a flowchart of a method 1600 for determining thetemperature differential between two portions of the object 150,according to an embodiment. An illustrative order of the method 1600 isprovided below; however, it will be appreciated that one or more stepsof the method 1600 may be repeated, performed in a different order,and/or omitted altogether.

The method 1600 may include printing the object 150 with the 3D printer120, as at 1602. This may be similar to at least a portion of the method200 described above with reference to FIGS. 2A, 2B, and 3-8.

The method 1600 may also include contacting a first portion of theobject 150 with the first end 134A of the first electrical conductor132A, as at 1604. More particularly, this may include embedding thefirst end 134A at least partially within the object 150 during theprinting of the object 150. This may be similar to steps 202-210 in FIG.2A and FIGS. 3-6, as described above. The first end 134A of theelectrical conductor 132A may be in contact with the object 150 duringand/or after the printing of the object 150.

The method 1600 may also include contacting a second portion of theobject 150 with the first end 134B of the second electrical conductor132B, as at 1606. More particularly, this may include embedding thefirst end 134B of the second electrical conductor 132B at leastpartially within the object 150 during the printing of the object 150.This may be similar to steps 216-220 in FIG. 2B and FIG. 7, as describedabove. The first end 134B of the second electrical conductor 132B may bein contact with the object 150 during and/or after the printing of theobject 150.

As will be appreciated, the first and second portions of the object 150may have different temperatures. For example, the first portion may beor include one or more of the layers 151-153, and the second portion maybe or include one or more of the layers 154-156 (see FIGS. 3-8). Asdescribed above, the layers 151-153 may be deposited/printed before thelayers 154-156, and thus the layers 151-153 may be cooler than thelayers 154-156. In one embodiment, the temperature of the object 150 maybe varied (e.g., using the substrate 112, the heater 170, and/or thecooler 172), as described above with respect to steps 214, 224. This maycause the first portion and the second portion of the object 150 to havedifferent temperatures.

The method 1600 may also include connecting the first electricalconductor 132A and the second electrical conductor 132B, as at 1608.More particularly, this may include connecting the second end 135A ofthe first electrical conductor 132A and the second end 135B of thesecond electrical conductor 132B.

The method 1600 may also include connecting the first electricalconductor 132A and the second electrical conductor 132B to thethermocouple reader 190, as at 1610. More particularly, the second ends135A, 135B may be connected to the thermocouple reader 190.

The method 1600 may also include determining a temperature differentialbetween the first and second portions of the object 150 using theelectrical conductors 132A, 132B and/or the thermocouple reader 190, asat 1612. The temperature differential between the first and secondportions may create an electro-motive force, which causes a variation(e.g., increase) in voltage that corresponds to the temperaturedifferential. Thus, determining the temperature differential may includemeasuring a voltage differential between the first and second portionsof the object 150 using the electrical conductor 132A. A lookup tableand/or an equation may then be used to determine the temperaturedifferential based at least partially upon the voltage differential.

In at least one embodiment, the method 1600 may also include varying thetemperature of the object 150 in response to the temperaturedifferential, as at 1614. This may be similar to step 214, 224, 1012,1014, or a combination thereof, and for the sake of brevity, the detailsare not discussed again here.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the present teachings are approximations, thenumerical values set forth in the specific examples are reported asprecisely as possible. Any numerical value, however, inherently containscertain errors necessarily resulting from the standard deviation foundin their respective testing measurements. Moreover, all ranges disclosedherein are to be understood to encompass any and all sub-ranges subsumedtherein. For example, a range of “less than 10” may include any and allsub-ranges between (and including) the minimum value of zero and themaximum value of 10, that is, any and all sub-ranges having a minimumvalue of equal to or greater than zero and a maximum value of equal toor less than 10, e.g., 1 to 5.

While the present teachings have been illustrated with respect to one ormore implementations, alterations and/or modifications may be made tothe illustrated examples without departing from the spirit and scope ofthe appended claims. For example, it may be appreciated that while theprocess is described as a series of acts or events, the presentteachings are not limited by the ordering of such acts or events. Someacts may occur in different orders and/or concurrently with other actsor events apart from those described herein. Also, not all processstages may be required to implement a methodology in accordance with oneor more aspects or embodiments of the present teachings. It may beappreciated that structural objects and/or processing stages may beadded, or existing structural objects and/or processing stages may beremoved or modified. Further, one or more of the acts depicted hereinmay be carried out in one or more separate acts and/or phases.Furthermore, to the extent that the terms “including,” “includes,”“having,” “has,” “with,” or variants thereof are used in either thedetailed description and the claims, such terms are intended to beinclusive in a manner similar to the term “comprising.” The term “atleast one of” is used to mean one or more of the listed items may beselected. Further, in the discussion and claims herein, the term “on”used with respect to two materials, one “on” the other, means at leastsome contact between the materials, while “over” means the materials arein proximity, but possibly with one or more additional interveningmaterials such that contact is possible but not required. Neither “on”nor “over” implies any directionality as used herein. The term“conformal” describes a coating material in which angles of theunderlying material are preserved by the conformal material. The term“about” indicates that the value listed may be somewhat altered, as longas the alteration does not result in nonconformance of the process orstructure to the illustrated embodiment. The terms “couple,” “coupled,”“connect,” “connection,” “connected,” “in connection with,” and“connecting” refer to “in direct connection with” or “in connection withvia one or more intermediate elements or members.” Finally, the terms“exemplary” or “illustrative” indicate the description is used as anexample, rather than implying that it is an ideal. Other embodiments ofthe present teachings may be apparent to those skilled in the art fromconsideration of the specification and practice of the disclosureherein. It is intended that the specification and examples be consideredas exemplary only, with a true scope and spirit of the present teachingsbeing indicated by the following claims.

What is claimed is:
 1. An object printed by a three-dimensional (3D)printer, the object comprising: a plurality of layers of materialprinted by the 3D printer, wherein the layers of material bond togetherto form the object as the layers of material cool and solidify afterbeing printed by the 3D printer; and a temperature sensor placed incontact with one or more of the layers when the layers of material arebeing printed by the 3D printer, wherein the temperature sensor remainsin contact with the object after the layers of material cool andsolidify to form the object, and wherein the temperature sensor isconfigured to measure a temperature of the object after the layers ofmaterial cool and solidify to form the object.
 2. The object of claim 1,wherein the temperature sensor is also configured to measure thetemperature of the object as the layers of material are being printed bythe 3D printer.
 3. The object of claim 1, wherein the layers of materialcomprise: a first layer of material; a second layer of materialpositioned on the first layer of material, wherein a recess is formed inthe second layer of material; and a third layer of material positionedon the second layer of material, wherein the temperature sensor ispositioned at least partially in the recess before the third layer ofmaterial is positioned on the second layer of material.
 4. The object ofclaim 3, wherein the layers of material comprise a metal.
 5. The objectof claim 1, wherein the temperature sensor comprises a thermocouplecomprising two electrical conductors that are made of differentmaterials.
 6. An object printed by a three-dimensional (3D) printer, theobject comprising: a first layer of material printed by the 3D printer;a second layer of material printed by the 3D printer onto the firstlayer of material, wherein a recess is formed in the second layer ofmaterial; and a third layer of material printed by the 3D printer ontothe second layer of material, wherein the first, second, and thirdlayers of material bond together to form the object as the first,second, and third layers of material cool and solidify after beingprinted by the 3D printer; and a first temperature sensor positioned atleast partially within the recess when the first, second, and thirdlayers of material are being printed by the 3D printer, wherein thefirst temperature sensor remains positioned at least partially withinthe recess after the first, second, and third layers of material cooland solidify to form the object, and wherein the first temperaturesensor is configured to measure a temperature of the object before andafter the first, second, and third layers of material cool and solidifyto form the object.
 7. The object of claim 6, wherein the first, second,and third layers of material comprise aluminum.
 8. The object of claim7, wherein the object is part of a vehicle.
 9. The object of claim 6,further comprising: additional layers of material that have a differentsize than the first layer of material, the second layer of material, thethird layer of material, or a combination thereof; and a secondtemperature sensor positioned at least partially within the additionallayers of material when the additional layers of material are beingprinted by the 3D printer, wherein the second temperature sensor remainspositioned at least partially within the additional layers of materialafter the additional layers of material cool and solidify to form theobject, and wherein the second temperature sensor is configured tomeasure the temperature of the object before and after the additionallayers of material cool and solidify to form the object.
 10. The objectof claim 9, wherein the first and second temperature sensors areconfigured to measure different temperatures due to the additionallayers of material having the different size.
 11. A method fordetermining a temperature of an object, the method comprising: printingthe object using a three-dimensional (3D) printer; measuring thetemperature of the object using a first temperature sensor while theobject is being printed by the 3D printer, wherein the first temperaturesensor is in contact with the object; and measuring the temperature ofthe object using the first temperature sensor after the object has beenprinted by the 3D printer.
 12. The method of claim 11, wherein printingthe object comprises forming a recess in the object using the 3Dprinter, and where the method further comprises positioning the firsttemperature sensor at least partially within the recess while the objectis being printed by the 3D printer such that the first temperaturesensor becomes at least partially embedded within the object.
 13. Themethod of claim 12, wherein the first temperature sensor remainsembedded within the object after the object has been printed by the 3Dprinter.
 14. The method of claim 11, further comprising varying thetemperature of the object, in response to the temperature measured whilethe object is being printed, to maintain the object within a firstpredetermined temperature range.
 15. The method of claim 14, furthercomprising varying the temperature of the object, in response to thetemperature measured after the object has been printed, to maintain theobject within a second predetermined temperature range, wherein thefirst predetermined temperature range is greater than the secondpredetermined temperature range.
 16. The method of claim 11, furthercomprising: measuring the temperature of the object using a secondtemperature sensor while the object is being printed by the 3D printer,wherein the first and second temperature sensors are embedded at leastpartially within the object while the object is being printed by the 3Dprinter; and measuring the temperature of the object using the secondtemperature sensor after the object has been printed by the 3D printer.17. The method of claim 16, wherein the first temperature sensor isembedded at least partially within a first portion of the object,wherein the second temperature sensor is embedded at least partiallywithin a second portion of the object, and wherein the first portion islarger than the second portion such that the first portion heats, cools,or both at a slower rate than the second portion.
 18. The method ofclaim 17, further comprising varying the temperature of the object whenthe temperature measured by the first temperature sensor after theobject has been printed is within a predetermined range and thetemperature measured by the second temperature sensor after the objecthas been printed is outside of the predetermined range.
 19. The methodof claim 11, further comprising coupling the object to a vehicle afterthe object has been printed, and wherein measuring the temperature ofthe object using the first temperature sensor after the object has beenprinted by the 3D printer comprises measuring the temperature of theobject using the first temperature sensor after the object has beencoupled to the vehicle.
 20. The method of claim 19, further comprisingvarying a temperature of the object in response to the temperaturemeasured after the object has been coupled to the vehicle using aheater, a cooler, or both that is coupled to the vehicle.